EP1674633B1 - Wood fiber insulating panel or mat - Google Patents

Abstract

Wood fiber insulating material plate or mat has three-dimensional adjustment of the wood fibers and thermoplastic binding fibers with a thickness of 3 to 350 mm. It has gross densities from 20 to 300 kg/m 3>and a portion of synthetic resin granulates from 5 to 45 percent, primarily in quantities from 10 to 40 percent and in particular in quantities from 22 to 37 percent.

Description

The invention relates to wood fiber insulation panels or mats with improved properties.

Methods for producing wood fiber insulating panels or mats are known. So wood fiber insulation boards or mats are produced by wet process. The plates or mats produced by these methods are relatively thin and the cost of manufacturing high, in particular, incur high costs for drying.

It is also known to produce mats using wood fibers or other fibrous natural products in conjunction with plastic fibers. These mats are made on known from the textile industry carding machines. These plates have only a small thickness. If thicker plates are desired, several of the originally obtained plates are superimposed in layers.

Furthermore, from the DE 100 56 829 a method for the production of insulating panels or mats made of wood fibers and plastic fibers, in which the plates have a thickness of about 20 mm and made in one operation become. The wood fibers are mixed with thermoactivatable plastic fibers or adhesive particles or biodegradable plastic binder fibers together in the desired ratio, loosely sprinkled in a single layer on an endless screen belt, compressed by a arranged over the first sieve belt second sieve belt or calibrated and then in a downstream Heating unit solidified.

The resulting wood fiber insulation panels are characterized by a layered construction, since the fibers are aligned when scattering on the screen belt more or less aligned in one direction, as is generally known from the manufacturing process of MDF boards.

Such plates, which are used for the insulation or for panel production, have a low transverse tensile strength. The individual layers can be easily separated from each other with insulation boards.

In order to increase the transverse tensile strength, it is further known in plate making to spread the starting materials in multiple layers, with the scattering direction rotated by 90 ° in each case. The product obtained is then pressed. This gives the known OSB board (Oriented Strands Board). This product can also be obtained by using the usual procedure. In this case, the mass obtained on the conveyor belt is slightly compressed, the product obtained in the further process process cut into adapted pieces, these offset by 90 ° each placed over one another and endverpresst. Although the products thus obtained show an improved transverse tensile strength, the production is time-consuming and requires a high investment in equipment.

The invention has for its object to provide single-ply Holzfaserdämmstoffplatten or mats with a large thickness range with good transverse tensile strength and compressive rigidity and a large density range.

This object is solved by the characterizing features of the claim. Particular embodiments can be found in the characterizing features of the subclaims 2 to 13.

The wood fiber insulation boards or mats according to the invention show a spatial orientation of the wood fibers and the binding fibers and have layer thicknesses of 3 to 350 mm at densities of 20 to 300 kg / m ³ . For the production of wood fiber insulation panels or mats according to the invention preferably devices are used, as they are known for the production of nonwovens by the nonwoven method and developed by the company DOA in A-4600 Wels.

To produce the wood fiber insulation boards or mats according to the invention, the wood fibers are used with a moisture content of 7 to 16%, in particular 12 to 14%.

If wood fibers are used, which are obtained in a refiner made of wood pulped, they are previously mixed in a conventional manner with flame retardants and / or water repellents in amounts of 8 to 30%, in particular 10 to 20% and dried to the desired moisture content while removing dust and fibers of small lengths or diameters.

Usually, the addition of the flame retardant and / or water repellents and the drying of the wood fibers is separated from the inventive production of wood fiber insulation panels or mats instead.

In addition to the wood fibers, other natural fibers, such as hemp, flax, sisal, can be used in addition to the wood fibers in order to achieve certain desired properties in the wood fiber insulation panels or mats according to the invention.

According to the desired composition, the individual components are weighed by separate weighing devices and entered via a blow pipe in the reservoir.

For the production of the wood fiber insulation boards or mats according to the invention, the wood fibers are used to bind fibers in mixing ratios of 95 to 80 to 5 to 20% and preferably of 90 to 10%. In these material mixtures up to 30% of the wood fibers can be replaced by other natural fibers.

The amount of supplied fiber mixture on a first conveyor belt depends on the desired layer thickness and bulk density of the produced wood fiber insulation board or mat, the bulk densities are between 20 to 300 kg / m ³ . In the resulting batt, the orientation of the fibers is three-dimensional.

To improve the compressive strength, a thermally activated plastic granulate is sprinkled on the pre-fleece. Plastic granules, such as those used in the recycling of plastic articles from the dual system, are very suitable for this purpose. Likewise, granules can be used, which consist of a thermally resistant core and a sheath of synthetic resins, which soften at the temperatures used in the heating zone. The plastic granules can be added in amounts of 5 to 45%, especially in amounts of 10 to 40% and in particular in amounts of 22 to 37%, based on the particular fiber mixture used. The fleece is fiberized at the end of the first conveyor belt. The resulting mixture is applied to a second conveyor belt with three-dimensional orientation of the fibers in the desired layer thickness. The layer thickness of the mat can be between 3 to 400 mm.

On the endless mat thus obtained, either woven or nonwovens of organic, inorganic or natural fibers are optionally applied on one or both sides. Likewise, webs of cellulose or foils are conceivable. The applied fabrics, nonwovens or webs are structured and / or perforated. Likewise, a coloring is possible. This makes it possible to improve the desired properties of the wood-fiber insulating panels or mats according to the invention.

The mats thus obtained are transferred to an endless oven belt and passed through the heating / cooling furnace. It is softened by the temperatures prevailing in the furnace, the binder fiber and the resin granules and thus activated. The temperatures in the heating zone are 130 to 200 ° C and especially 160 to 185 ° C. Both the binding fibers and the resin granules provide an intimate connection with the wood fibers and possibly laid fabric webs or films.

In the heating furnace, a calibration zone adjoins the heating zone, in which the mats are uniform in their thickness and, if desired, compressed to the final thickness of the wood fiber insulation panels or mats according to the invention. Thus, the resulting mats are compressed to thicknesses of 3 to 350 mm, in particular 4 to 250 mm.

After calibration, the resulting mats are fed to the oven belt of a cooling zone and then the final processing is carried out to the desired invention Holzfaserdämmstoffplatten or mats. The mat is trimmed at the edges and then split longitudinally and / or transversely.

There are wood fiber insulation boards or mats are produced, which are characterized by the wide range of plate thickness of 3 to 350 mm, in particular 4 to 250 mm at densities of 20 to 300 kg / m ³ and also show improved compressive stiffness in addition to an improved transverse tensile strength.

The wood fiber insulation panels or mats according to the invention are as acoustic insulation panels, as impact sound insulation mats for laminate or parquet floors, as penetration-resistant insulation board, as thermal insulation composite board, as Innensparrendämmung u.ä. used. By additionally applied on one or both sides webs of nonwovens, fabrics u.ä. from inorganic, organic or natural fibers, or films that may be structured, perforated, dyed, the range of applications of wood fiber insulation panels or mats according to the invention is further increased.

The invention will be explained in more detail by way of examples, wherein Examples 1-6 and 9 are not part of the invention.

Example 1:

For the production of a wood fiber insulation board 10 parts binding fibers with 90 parts of wood fibers, which were previously provided with flame retardants, mixed and inflated evenly over a reservoir on a first conveyor belt after weighing, so that the density of 30 to 60 kg / m ³ , in particular 35 to 45 kg / m ³ . At the end of the first conveyor belt, the pre-fleece is tufted and inflated after loosening on a second conveyor belt with a thickness between 60 to 250 mm and transferred to the resulting endless mat on the oven belt. After the heating zone, the mat was spent without much compaction, but only homogenization in the cooling zone and then divided to the desired dimensions.

Example 2:

For the production of a wood fiber insulation board as an acoustic panel, as described in Example 1, the material is inflated onto the second conveyor belt and covered after construction of the desired layer thickness on one side with a perforated nonwoven fabric in ribbon form. In the heating furnace, the binding fibers ensure a connection of the wood fibers and a connection of the laid-up fleece to the formed wood fiber insulation board.

Example 3:

For the production of absorbers or resonators 88 parts of wood fibers are mixed with 12 parts of binder fibers and inflated from the reservoir in quantities on a first conveyor belt, which is achieved a bulk density of 35 to 100 kg / m ³ in the mat. After crushing the resulting fleece at the end of the conveyor belt 1, the material is on a second conveyor belt in thicknesses between 30 to 120 mm inflated. The resulting mat is further treated as described in Example 1.

Example 4:

For the production of wood fiber insulating materials for use in acoustics, 10 parts of binder fibers are mixed with 75 parts of wood fibers and 15 parts of flax fibers and uniformly inflated via a storage container onto a first conveyor belt to obtain a final product with a bulk density of 35 to 130 kg / m ³ becomes. Under comminution of the pre-fleece at the end of the first conveyor belt and repeated mixing, the material of the pre-fleece is inflated to a layer thickness of 4 to 200 mm on the second conveyor belt. The resulting continuous mat is further treated as described in Example 1.

Example 5:

For the production of a wood fiber / hemp fiber insulation board 12 parts binder fibers, 60 parts wood fibers and 28 parts hemp fibers are mixed together. The material is inflated uniformly from the storage container in such quantities on a first conveyor belt, the bulk densities of 25 to 50 kg / m ³ , in particular 25 to 40 kg / m ³ , are obtained. Under repeated mixing of the components of the Vorvlieses from the first conveyor belt, the mass is uniformly inflated to a second conveyor belt. The speed of the second conveyor belt is adjusted so that mat thicknesses of 80 to 250 mm are obtained. The further processing is carried out in the manner described in Example 1.

All of the wood fiber insulation panels or mats obtained in the aforementioned examples exhibit a higher transverse tensile strength than those previously known for the same purposes wood fiber insulation panels or mats.

Example 6:

For the production of wood fiber insulation mats as impact sound mats in laminate or parquet floors 11 parts binding fibers with 89 parts of wood fibers are mixed together and fed to the reservoir. For this, the fiber mixture is inflated to a first conveyor belt to a uniform web, which has a bulk density of 150 to 280 kg / m ³ , in particular 150 to 180 kg / m ³ , has. Prior to the repeated mixing of the fibers at the end of the first conveyor belt, a plastic granulate, as obtained during the recycling of synthetic resin products from the dual system, is applied in quantities by means of a powder spreader arranged over the entire width of the first conveyor belt, in the obtained nonwoven on the second conveyor belt a ratio of wood fibers to binder fibers to resin granules of 55: 7: 38 is given. The mat thickness on the second conveyor belt is 5 to 10 mm. The obtained endless mat of the second conveyor belt is transferred to the oven belt, heated in the heating zone with hot air to 170 to 180 ° C and pulled through the calibration zone. Here a small compression takes place on the final mat thickness of 3 to 8 mm. These mats show in addition to a good transverse tensile strength improved pressure rigidity.

Example 7:

There are 8 parts of binder fiber mixed with 75 parts of wood fibers and 17 parts of hemp fibers and fed to the reservoir. For this, the fiber mixture is uniformly inflated to a first conveyor belt, so that a nonwoven fabric with a density of 130 to 220 kg / m ³ and in particular from 150 to 180 kg / m ³ is formed. After the fibrous web has been formed, granules are added via the powder spreader which consist of a thermally resistant core and a casing of synthetic resins which soften at the temperatures prevailing in the heating zone. The added amount of granules is so high that a part of granules is present on two parts of the fiber mixture. The fiber mixture is well mixed by tearing at the end of the first conveyor belt with the granules and inflated onto the second conveyor belt. In this case, the rotational speed of the second conveyor belt is adjusted so that an endless mat with a thickness of 20 to 22 mm is formed. On the mat is placed on one side of a profiled fabric fleece made of cellulose fibers over the entire width of the mat. The product thus obtained is transferred to the oven belt and heated to 170 ° C. At this temperature, the product is driven through the sizing rolls and compacted to the final thickness of 8 to 15 mm. The obtained Holzfaserdämmstoffplatten are excellently suitable as Unterlegplatten in drywall.

Example 8:

For the production of wood fiber insulation boards, which can be used for example as Aufsparrendämmung and walkable but not necessarily puncture-resistant, 11 parts of binder fibers are mixed with 89 parts of wood fibers and fed to the reservoir. From the reservoir, the fiber mixture is inflated in quantities on a first conveyor belt, so that end products have a bulk density of 70 to 150 kg / m ³ and in particular from 100 to 140 kg / m ³ . On the Vorvlies thus obtained are on a powder spreader Added granules, which consist of a heat-resistant core and a softening in the heating zone sheath and / or consist of resin granules which are obtained in the recycling of plastic articles from the dual system. The amount of added granules is 28 parts granules to 72 parts of the fiber mixture.

The pre-fleece with the scattered granules is crushed and blended well mixed on the second conveyor belt inflated. The speed of the second conveyor belt is set so that the resulting endless mat has a thickness of 65 to 180 mm. The mat is provided on one side with a dense, moisture-repellent film and on the other side with a fabric fleece. The prepared from both sides coated mat is passed from the second conveyor belt on the oven belt, heated in the heating zone to 175 ° C and compressed in the calibration to a final thickness of 60 to 160 mm.

In the heating and calibration zone, a good matrix is formed by the softening binder fibers and the granules, into which the wood fibers are embedded and which ensure sufficient bonding of the applied film or fabric fleece.

Example 9:

For the production of ETICS carrier plates, 12 parts of binder fibers are mixed with 88 parts of wood fibers and fed to a storage container. The procedure is as described in Example 8, with the difference that a bulk density of 80 to 140 kg / m ³ and in particular from 95 to 105 kg / m ^{3 is} achieved and the granules in amounts of 37 parts to 63 parts of fiber mixture was added. After intimate mixing of the fiber mixture with the granules at the end of the first conveyor belt, the mixture is inflated to a second conveyor belt. The speed of the second conveyor belt is adjusted so that an endless mat with a thickness of 75 to 280 mm is formed. After transfer to the oven belt is heated to 175 ° C and compacted by the sizing to a final thickness of 60 to 200 mm. The resulting plates show excellent compressive stiffness and very good transverse tensile strength.

Example 10:

For the production of puncture-proof wood fiber insulation boards, 13 parts of binding fibers are mixed with 78 parts of wood fibers and 9 parts of flax fibers and fed to a storage container. From the storage container, the fiber mixture is inflated onto the first conveyor belt, in quantities that give a plate with a density of 170 to 270 kg / m ³ and in particular from 230 to 250 kg / m ³ . On the formed web on the first conveyor belt granules are spread, which are obtained by recycling of plastic articles from the dual system, in quantities of 36 parts of granules to 64 parts of fiber mixture.

For uniform distribution of the granules in the fiber mixture, the fleece is torn open at the end of the first conveyor belt, the material is well mixed and then inflated to a second conveyor belt. In this case, the rotational speed of the second conveyor belt is adjusted so that an endless mat with a thickness of 25 to 90 mm is obtained.

On this mat a structured fiber fleece, preferably a random fiber fleece over the entire width of the endless mat is placed on one side.

The product thus obtained is transferred to the oven belt and heated in the heating zone to 175 to 185 ° C. In the calibration zone is compressed to a thickness of 15 to 60 mm and then cooled. The spatial arrangement of the fibers is maintained even after calibration. The mats obtained show a high compressive stiffness combined with an increased transverse tensile strength.

Claims (13)

1. Single-layer wood fibre insulating material board or mat having increased transverse tensile strength, with a three-dimensional alignment of the wood fibres and of the thermoplastic binder fibres, a thickness of 3 to 350 mm, in particular 4 to 250 mm, bulk densities of 20 to 300 kg/m³ characterized by a wood fibre to binder fibre ratio of 95 to 80% to 5 to 20% and a proportion of synthetic resin granules in quantities of 5 to 45%, primarily in quantities of 10 to 40% and in particular in quantities of 22 to 37% based on the wood fibre-binder material mixture, and structured and/or perforated woven fabrics or nonwovens of inorganic, organic or natural fibres, webs of cellulose or films applied to one and/or both sides.
2. Wood fibre insulating material board or mat according to Claim 1, characterized by a replacement of the wood fibres by other natural fibres in quantities up to 30%.
3. Wood fibre insulating material board or mat according to Claims 1 or 2, characterized by a thickness of 60 to 250 mm and a bulk density of 30 to 60 kg/m³, in particular 35 to 45 kg/m³.
4. Wood fibre insulating material board or mat as a wood fibre acoustic insulating board, according to Claim 1 or 2, characterized by a thickness of 60 to 250 mm and a bulk density of 35 to 45 kg/m³ and a perforated fibre nonwoven laid on one side.
5. Wood fibre insulating material board or mat for absorbers or resonators, according to Claim 1 or 2, characterized by a thickness of 30 to 120 mm and a bulk density of 35 to 100 kg/m³.
6. Wood fibre insulating material board or mat according to Claim 1 or 2, characterized by the partial replacement of the wood fibres by flax fibres, a thickness of 80 to 250 mm and a bulk density of 25 to 50 kg/m³, in particular 25 to 40 kg/m³.
7. Wood fibre insulating material board or mat as a wood fibre footfall sound insulating mat for laminated or parquet floors, according to Claim 1 or 2, characterized by a thickness of 3 to 8 mm, a bulk density of 150 to 280 kg/m³, in particular 170 to 255 kg/m³, and a proportion of synthetic resin granules and slight compaction of the mat in the heating/cooling oven.
8. Wood fibre insulating material board or mat as an underlay board in dry construction, according to Claim 1 or 2, characterized by a thickness of 8 to 15 mm with a bulk density of 130 to 220 kg/m³, in particular of 150 to 180 kg/m³, a proportion of synthetic resin granules, a profiled woven fabric fleece applied to one side of the mat and compaction of the mat in the heating/cooling oven.
9. Wood fibre insulating material board or mat as a wood fibre above-rafter insulating board, according to Claim 1 or 2, characterized by a thickness of 60 to 160 mm with a bulk density of 70 to 150 kg/m³, in particular 100 to 140 kg/m³, a proportion of synthetic resin granules and compaction of the mat in the heating/coating oven.
10. Wood fibre insulating material board or mat as a wood fibre above-rafter insulating board, according to Claim 1 or 2, characterized by a thickness of 60 to 160 mm with a bulk density of 70 to 150 kg/m³, in particular 100 to 140 kg/m³, a proportion of synthetic resin granules and a moisture-repellent film laid on one side of the mat and a woven fabric fleece laid on the other side, and compaction of the mat in the heating/cooling oven.
11. Wood fibre insulating material board or mat as a wood fibre WDVS (thermal insulation composite system) loadbearing board, according to Claim 1 or 2, characterized by a thickness of 60 to 200 mm with a bulk density of 80 to 150 kg/m³ and in particular of 95 to 105 kg/m³, a proportion of synthetic resin granules and forcible compaction of the endless mat in the heating/cooling oven.
12. Wood fibre insulating material board or mat as a wood fibre insulating material board secure against passage, according to Claim 1 or 2, characterized by a thickness of 15 to 60 mm with a bulk density of 170 to 270 kg/m³, in particular 230 to 250 kg/m³, a high proportion of synthetic resin granules and very forcible compaction of the endless mat in the heating/cooling oven.
13. Wood fibre insulating material board or mat as a wood fibre insulating material board secure against passage, according to Claim 1 or 2, characterized by a thickness of 15 to 60 mm with a bulk density of 170 to 270 kg/m³, in particular 230 to 250 kg/m³, a high proportion of synthetic resin granules, a structured fibre nonwoven applied to one side of the endless mat and very forcible compaction of the endless mat in the heating/cooling oven.